Assembly Device for Inserting a Stator of an Electric Machine into a Transmission Housing, Hybrid Drive Module, and Method for Mounting a Stator

Abstract

An assembly device (29) for inserting a stator (4) of an electric machine (3) into a bell-shaped transmission housing (1) includes an inner guide element (38), which is guidable, in form-locking manner, relative to a rotor hub (9a) or a transmission input shaft (6) accommodating the rotor hub (9a), and an outer guide element (37), which is guidable in form-locking manner at the transmission housing (1). The guide elements (37 and 38) are radially spaced apart and fixed to each other with at least one radially extending connecting element (39). At least one sliding member (30) is longitudinally displaceably guided in the connecting element (39) and includes a first, radially outer sliding member part (31) for form-locking engagement at an outer circumference of the stator (4) and a second, radially inner sliding member part (32) for engagement at an end face of the stator (4).

Claims

1-11. (canceled)

12. An assembly device (29) for inserting a stator (4) of an electric machine (3) of a hybrid drive module (2) into a bell-shaped transmission housing (1), a rotor (5) of the electric machine (3) at least indirectly connected to a transmission input shaft (6) via a rotor carrier (9) and a rotor hub (9a), a stator (4) of the electric machine (3) extending concentrically to the rotor (5), radially surrounding the rotor (5), and securable at the transmission housing (1), the assembly device (29) comprising: an inner guide element (38) guidable, in a form-locking manner, with respect to the rotor hub (9a) or the transmission input shaft (6), the inner guide element (38) accommodating the rotor hub (9a); and an outer guide element (37) guidable, in a form-locking manner, at the transmission housing (1), wherein the inner and outer guide elements (37 and 38) are radially spaced apart from each other and are fixed to each other with at least one radially extending connecting element (39), wherein at least one sliding member (30) is longitudinally displaceably guided in the at least one radially extending connecting element (39), and the at least one sliding member (30) comprises two sliding member parts (31 and 32), which are adjustable with respect to each other, wherein a first, radially outer sliding member part (31) of the two sliding member parts (31 and 32) is configured for form-locking engagement at an outer circumference of the stator (4), and a second, radially inner sliding member part (32) of the two sliding member parts (31 and 32) is configured for engagement at an end face (27) of the stator (4).

13. The assembly device of claim 12, wherein centering pins (41) extend axially from the outer guide element (37), and the centering pins (41) are configured for engagement in through-bores (14) of the transmission housing (1), which extend in a mounting flange formed at the transmission housing (1).

14. The assembly device of claim 12, wherein the second sliding member part (32) is configured for form-locking engagement into the end face (27) such that the stator (4), in a certain rotational position relative to the transmission housing (1), is accommodated by the assembly device (29) and is insertable into the transmission housing (1).

15. The assembly device of claim 14, wherein the second sliding member part (32) comprises positioning pins (33) extending in an axial direction, and the positioning pins (33) are configured for engagement in centering bore holes (28) of the stator (4).

16. The assembly device of claim 12, wherein the first sliding member part (31) is couplable to a driving surface (27) provided at the outer circumference of the stator (4).

17. The assembly device of claim 12, wherein the first sliding member part (31) and the second sliding member part (32) are each a hollow-cylindrical, the second sliding member part (32) is displaceably guided in the first sliding member part (31), and claws (34, 35) extend axially from the first sliding member part (31).

18. A hybrid drive module (2) and an assembly device (29) for inserting a stator (4) of an electric machine (3) of a hybrid drive module (2) into a bell-shaped transmission housing (1), the bell-shaped transmission housing (1) radially surrounding the hybrid drive module (2), a rotor (5) of the electric machine (3) at least indirectly connected to a transmission input shaft (6) via a rotor carrier (9) and a rotor hub (9a), a stator (4) of the electric machine (3) extending concentrically to the rotor (5), radially surrounding the rotor (5), and secured at the transmission housing (1), the assembly device (29) comprising: an inner guide element (38) guidable, during an assembly process, in a form-locking manner with respect to the rotor hub (9a) or the transmission input shaft (6), the inner guide element (38) accommodating the rotor hub (9a); and an outer guide element (37) configured to guide the assembly device (29) is guided in a form-locking manner at the transmission housing (1), wherein the inner and outer guide elements (37 and 38) are radially spaced apart from each other and are fixed to each other with at least one radially extending connecting element (39), wherein at least one sliding member (30) is a claw (34, 35), is longitudinally displaceably guided in the connecting element (39), accommodates the stator (4), and is configured to guide the stator (4) with respect to the rotor hub (9a) and the transmission input shaft (6) as well as with respect to the transmission housing (1).

19. The hybrid drive module and the assembly device of claim 18, wherein: the sliding member (30) comprises two sliding member parts (31 and 32), which are adjustable with respect to each other; a first, radially outer sliding member part (31) of the two sliding member parts (31 and 32) engages in a form-locking manner at the outer circumference of the stator (4); and a second, radially inner sliding member part (32) of the two sliding member parts (31 and 32) engages at an end face (27) of the stator (4).

20. The hybrid drive module and the assembly device of claim 19, wherein: the stator (4) comprises bulges (21) at an external shell surface of the stator (4); the bulges (21) extend across a substantial portion of an axial length of the stator (4) and forming bolt-on surfaces (21a) at rear-side ends of the bulges (21); tabs (26) extend in a circumferential direction and protrude from a front section of the bulges (21); and the tabs (26) are each engaged from behind at a driving surface (27) by the first sliding member part (31).

21. The hybrid drive module and the assembly device of claim 20, wherein the tabs (26) comprise centering bore holes (28) extending in an axial direction, and positioning pins (33) of the second sliding member part (32) and locating pins (43) extending from the transmission housing (1) engage into the bore holes (28) in the mounted condition of the stator (4) during the assembly process.

22. A method for mounting a stator (4) of an electric machine (3) of a hybrid drive module (2) into a bell-shaped transmission housing (1), a rotor (5) of the electric machine (3) inserted into the bell-shaped transmission housing (1), the method comprising: grasping the stator (4) by two sliding member parts (31 and 32) of an assembly device (29) at an end face and at a driving surface (27) provided at an outer circumference of the stator (4); aligning the assembly device (29) in a radial direction as well as in a circumferential direction with respect to the assembly device (29); centering the assembly device (29) in front of an end of the transmission housing (1); aligning an outer guide element (37) via bore holes (14) provided in a flange of the transmission housing (1); and centering one or both of a rotor hub (9a) and a transmission input shaft (6) at an inner guide element (38); with a sliding member (30) formed by the two sliding member parts (31 and 32), displacing the stator (30) into a radial space between the rotor (4) and the transmission housing (1) until centering bore holes (28) provided at the stator (4) slide onto centering pins (43) protruding from the transmission housing (1); bolting the stator (4) to the transmission housing (1) with axially extending bolts (22); and separating the assembly device (29) from the stator (4) and, thereafter, from the transmission housing (1) and the one or both of the rotor hub (9a) and the transmission input shaft (6).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] One advantageous embodiment of the invention, which is explained in the following, is represented in the drawings. Wherein:

[0031] FIG. 1 shows a part view including a longitudinal section through a transmission housing including a hybrid drive module arranged therein, which essentially includes an electric machine, a separating clutch, and a pre-ratio stage,

[0032] FIG. 2 shows, as a part view, a schematic related to the alignment and fixation of the stator in the transmission housing,

[0033] FIG. 3 shows a perspective representation of the stator, wherein the sliding member parts of the assembly device are placed onto the stator, as illustrated with the aid of a direction arrow,

[0034] FIG. 4 shows a perspective representation of the stator in the area of a radial bulge,

[0035] FIG. 5 shows, as a schematic, the fixation of the stator in the sliding member of the assembly device,

[0036] FIG. 5a shows the assembly device, which engages at the transmission housing and, via a hollow shaft, at a transmission input shaft,

[0037] FIG. 5b shows the threading of the stator onto centering pins, which are arranged in the transmission housing,

[0038] FIG. 5c shows the insertion of mounting bolts into the stator and a bracing of the stator with the transmission housing, and

[0039] FIG. 5d shows the separation of the assembly device from the stator, the transmission input shaft, and the transmission housing.

DETAILED DESCRIPTION

[0040] Reference will now be made to embodiments of the invention, one or more examples of which are shown in the drawings. Each embodiment is provided by way of explanation of the invention, and not as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be combined with another embodiment to yield still another embodiment. It is intended that the present invention include these and other modifications and variations to the embodiments described herein.

[0041] In FIG. 1, a front section of a transmission housing is labeled by 1; the front section is designed to be bell-shaped in the manner of a clutch housing, in order to be bolted to a crankcase (not described in greater detail) of an internal combustion engine. The transmission housing 1 accommodates, in an interior of the transmission housing 1, a hybrid drive module 2, which includes an electric machine 3 with a stator 4, which is rotationally fixed with respect to the transmission housing 1, and a rotary rotor 5. A further integral part of the hybrid drive module 2 is a transmission input shaft 6 for a transmission (not represented in greater detail) positioned downstream from the hybrid drive module 2, wherein a torsion damper 7 and a hydraulically actuated separating clutch 8 designed as a multi-disk clutch are mounted on the transmission input shaft 6. A rotor carrier 9 connected to the rotor 5 drives a planetary gear stage 10, which includes a ring gear 11 connected to the rotor carrier 9 in a form-locking manner, planet gears 12, and a sun gear 13, wherein the rotor carrier 9 is arranged via a rotor hub 9a on the transmission input shaft 6.

[0042] In addition, it is apparent from FIG. 1 that the transmission housing 1 is provided with multiple through-bores 14, which are distributed around a circumference of the transmission housing 1, as well as with a mounting face 15. With the aid of internal hexagon bolts 16, a bearing shield 17 is braced at the mounting face 15 with the transmission housing 1. Located on one side of the bearing shield 17 is a wet space 18 accommodating the hybrid drive module 2 and the planetary gear stage 10 and, located on the other side is a dry space 20, in which a dual-mass flywheel 19, among other things, is located. Before the mounting of the stator 4, which is explained in the following, the assembly including the rotor 5, the rotor carrier 9, and the planetary gear stage 10, are slid onto the transmission input shaft 6.

[0043] In FIG. 2, an upper subsection of the transmission housing 1 is diagrammatically represented, in order to illustrate how the stator 4 is to be secured therein. Accordingly, the stator 4as is explained in detail in the following in conjunction with FIG. 4includes multiple bulges 21 at an outer circumference of the stator 4, through which bore holes 23 accommodating mounting bolts 22 extend. Inwardly projecting flange segments 24 protrude from the transmission housing 1, into which the mounting bolts 22 engage with the aid of their external thread.

[0044] FIG. 3 shows the stator 4, from whose laminated cores 25 the radially outward projecting bulges 21 protrude, which extend along the axial length of the laminated cores 25. Each of the bulges 21 includes a bore hole 23. Tabs 26, which have a shorter axial length as compared to the bulges 21, are located next to the bulges 21 on the external shell surface of the laminated cores 25. As a result, driving surfaces 27 are formed at the tabs 26. For the rest, centering bore holes 28 extend through the tabs 26.

[0045] In FIG. 3, an assembly device 29 is placed onto the stator 4, of which a sliding member 30 is visible in the representation; the sliding member 30 is constructed of a hollow-cylindrical, first sliding member part 31 and a likewise hollow-cylindrical, second sliding member part 32. The second sliding member part 32 is longitudinally displaceably guided in the first sliding member part 31 and includes positioning pins 33, with the aid of which the stator 4 is aligned with respect thereto in the circumferential direction, in that the positioning pins 33 engage into the centering bore holes 28 of the tabs 26. Axial extensions 34, at the ends of which engaging pieces 35 are located, are an integral part of the first sliding member part 31. Initially, the first sliding member part 31 is moved axially to such an extent that the engaging pieces 35 are located in a plane with the driving surfaces 27 of the tabs 26. Thereafter, a turn of the first sliding member part 31 takes place, and so the engaging pieces 35 engage, in the manner of bayonets, at the tabs 26. Therefore, the stator is fixed at an end face of the tabs 26 and, on the other hand, at the driving surfaces 27.

[0046] FIG. 4 shows the stator 4 without the assembly device 29 placed thereon, and so the configuration of the bulges 21 is made clear. Mounting bolts 22 have already been inserted into the bore holes. With respect to a tab 26 represented in FIG. 4, it is apparent that the tab 26 is designed to be shorter than the bulge 21, whereby the driving surface 27 is formed at this end. In addition, a centering bore hole 28 is apparent from this view.

[0047] In FIGS. 5 and 5a-5d, individual method steps of a method for mounting the stator 4 of the electric machine 2 are represented. As is apparent from these figures, the assembly device 29 includes an outer guide element 37 and an inner guide element 38, which are connected to each other with the aid of a connecting element 39 extending radially therebetween. The connecting element 39 is designed as a disk 40. As is also apparent, centering pins 41, which extend axially, protrude from the outer guide element 37. The inner guide element 38 includes a recess 42. In addition, the sliding member 30 is longitudinally displaceably guided in the connecting element 39, wherein the sliding member 30 includes the first sliding member part 31 and the second sliding member part 32. The positioning pins 33 engage into the stator 4 on the end face, which takes place via the centering bore holes 28, as explained above.

[0048] The engaging pieces 35 formed at the extensions 34 of the first sliding member element 31 can be pivoted so far that the engaging pieces 35 can engage behind the driving surfaces 27. Thereafter, the assembly device 29, together with the stator grasped thereby, is centered in front of the end of the transmission housing 1. As a result, the centering pins 41 are inserted into the bore holes 14 and the inner guide element 38 indirectly engages at the transmission input shaft 6, in order to be centered at the transmission input shaft 6 and the drive elements arranged thereon, and, therefore, according to FIG. 5a, centers the transmission input shaft 6 and the unitsplanetary gear stage 10 and rotor 5-arranged thereon, with respect to the transmission housing 1. In addition, it is apparent from the representation according to FIG. 5a that multiple axially extending locating pins 43 are arranged therein.

[0049] According to FIG. 5b, the stator 4 is then slid, with the aid of the sliding member 30 of the assembly device 29, into the annular space formed between the rotor 5 and the transmission housing 1, wherein the locating pins 43 engage into the centering bore holes 28. According to FIG. 5c, the mounting bolts 22 are then screwed into the flange segments 24 (see FIG. 2) with the aid of a wrench 44. According to FIG. 5d, finally, a separation of the assembly device 29 from the transmission housing 1 and the stator 4 takes place.

[0050] Modifications and variations can be made to the embodiments illustrated or described herein without departing from the scope and spirit of the invention as set forth in the appended claims. In the claims, reference characters corresponding to elements recited in the detailed description and the drawings may be recited. Such reference characters are enclosed within parentheses and are provided as an aid for reference to example embodiments described in the detailed description and the drawings. Such reference characters are provided for convenience only and have no effect on the scope of the claims. In particular, such reference characters are not intended to limit the claims to the particular example embodiments described in the detailed description and the drawings.

REFERENCE NUMBERS

[0051] 1 transmission housing [0052] 2 hybrid drive module [0053] 3 electric machine [0054] 4 stator [0055] 5 rotor [0056] 6 transmission input shaft [0057] 7 torsion damper [0058] 8 hydraulically actuated separating clutch [0059] 9 rotor carrier [0060] 9a rotor hub [0061] 10 planetary gear stage [0062] 11 ring gear [0063] 12 planet gear [0064] 13 sun gear [0065] 14 through-bores [0066] 15 mounting face [0067] 16 internal hexagon bolt [0068] 17 bearing shield [0069] 18 wet space [0070] 19 dual-mass flywheel [0071] 20 dry space [0072] 21 bulge [0073] 21a bolting-on surface of 21 [0074] 22 mounting bolt [0075] 23 bore hole [0076] 24 flange segment [0077] 25 laminated cores [0078] 26 tab [0079] 27 driving surface [0080] 28 centering bore hole [0081] 29 assembly device [0082] 30 sliding member [0083] 31 first sliding member part [0084] 32 second sliding member part [0085] 33 positioning pin [0086] 34 extensions [0087] 35 engaging piece [0088] 36 end face of 26 [0089] 37 outer guide element [0090] 38 inner guide element [0091] 39 connecting element [0092] 40 disk [0093] 41 centering pin [0094] 42 recess in 38 [0095] 43 locating pin [0096] 44 wrench